Burster 86-2112 User manual

burster Italia s.r.l. · Sede legale ed operativa · Via Cesare Battisti, 16/18 · 24035 Curno (BG) · Tel. [phone] · Fax [phone]
e-mail: [e-mail] · http://www.burster.it
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Apparecchi di misura di precisione. Sensori e Sistemi
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Operation Manual
for Torque Sensor
For below and similar Types
86-2112
86-2112-R
86-2412
86-2412-R
86-2212
86-2212-R
86-2512
86-2512-R

burster Italia s.r.l. · Sede legale ed operativa · Via Cesare Battisti, 16/18 · 24035 Curno (BG) · Tel. [phone] · Fax [phone]
e-mail: [e-mail] · http://www.burster.it
C.F. e P.IVA 11048400151 · Capitale sociale Euro 49.920,00 ·R.E.A. di Bergamo 276749
Apparecchi di misura di precisione. Sensori e Sistemi
per grandezze elettriche, termiche e meccaniche
References in this Text
1.6 Warning Notes; Page 5
Attention must be paid to the accident prevention regulations of the trade associations.
Coverings and casings are necessary before operating the sensor. This is also valid for
commissioning, maintenance and trouble shooting.
Duties of the coverings and casings are:
⇒Protection from detaching parts
⇒Protection from contusion and shear
⇒Prevention from reaching rotating parts
⇒Prevention from being tangled up and/or getting caught by parts
Coverings may
⇒Not grind
⇒Not rotate
Coverings are also necessary outside of operating and motion travel areas of persons.
These demands can be modified if other sufficient safety devices are available. During
operation, the safety precautions must be operative. By vibrations, damages can occur at the
device.
4 Mechanical Assembly; Page 7
During the assembly, the sensor must be supported to protect if from falling down.
4.1.3 Alignment of the Measurement Arrangement; Page 7
For further references see coupling manual.
4.2 General; Page 7
Before the assembly, shafts must be cleaned with dissolver (e.g. acetone), no foreign particles
may adhere to them. The hub must fit corresponding to the connection.
Caution: During the assembly inadmissibly large forces may not act on the sensor or the
couplings. At small torques (< 20 N·m) connect the sensor electrically during the assembly and
observe the signal, the measurement signal may not exceed the limit values
4.2.1 Torque Sensors of 0,03 Nm to 15 Nm; Page 8
Sensors with nominal torques below 20 N·m are very sensitive to overload, therefore these
sensors need to be handled with greatest caution.
4.3 Freefloating Assembly; Page 8+9
Caution: During the assembly inadmissibly large forces may not act on the sensor or the
couplings.
In this installation case, double-jointed couplings can not be used for both sides!
Risk of Breakage!
4.4 Foot Version Assembly; Page 9
Caution: During the assembly inadmissibly large forces may not act on the sensor or the
couplings.
6.1 Engaging; Page 11
Warming-up period of the torque sensor is approx. 5 min.
6.4.2 Natural Resonances; Page 12
An operation of the device in natural resonance can lead to permanent damages.

burster Italia s.r.l. · Sede legale ed operativa · Via Cesare Battisti, 16/18 · 24035 Curno (BG) · Tel. [phone] · Fax [phone]
e-mail: [e-mail] · http://www.burster.it
C.F. e P.IVA 11048400151 · Capitale sociale Euro 49.920,00 ·R.E.A. di Bergamo 276749
Apparecchi di misura di precisione. Sensori e Sistemi
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Contents
1Read First..............................................................................................................................................................4
1.1 Safety and Caution Symbols .........................................................................................................................4
1.2 Intended Use.................................................................................................................................................4
1.3 Dangers.........................................................................................................................................................4
1.3.1 Neglecting of Safety Notes ....................................................................................................................4
1.3.2 Remaining Dangers...............................................................................................................................4
1.4 Reconstructions and Modifications................................................................................................................4
1.5 Personnel ......................................................................................................................................................4
1.6 Warning Notes...............................................................................................................................................4
2Term Definitions ....................................................................................................................................................5
2.1 Terms ............................................................................................................................................................5
2.2 Definition of the Pictograms on the Torque Sensor .......................................................................................5
3Product Description ...............................................................................................................................................5
3.1 Mechanical Setup..........................................................................................................................................5
3.2 Electrical Setup..............................................................................................................................................6
3.2.1 Sensors with Analog Output ..................................................................................................................6
3.2.2 Sensors with RS485 Interface ...............................................................................................................6
4Mechanical Assembly............................................................................................................................................7
4.1 Couplings.......................................................................................................................................................7
4.1.1 Misalignment Possibilities of Single-Jointed Couplings .........................................................................7
4.1.2 Double-Jointed Couplings......................................................................................................................7
4.1.3 Alignment of the Measurement Arrangement ........................................................................................7
4.2 General..........................................................................................................................................................7
4.2.1 Torque Sensors of 0,03 N·m to 15 N·m................................................................................................8
4.2.2 Torque Sensors from 20 N·m.................................................................................................................8
4.3 Freefloating Assembly...................................................................................................................................8
4.4 Foot Version Assembly..................................................................................................................................9
5Electrical Connection...........................................................................................................................................10
5.1 Pin Connection ............................................................................................................................................10
5.2 Calibration Control.......................................................................................................................................10
5.2.1 Calibration Control at Analog Output...................................................................................................10
5.2.2 Calibration Control at RS485...............................................................................................................11
5.3 Cable...........................................................................................................................................................11
5.4 Shielding Connection...................................................................................................................................11
5.5 Running of Measuring Cables .....................................................................................................................11
5.6 Angle (Option) .............................................................................................................................................11
6Measuring............................................................................................................................................................11
6.1 Engaging .....................................................................................................................................................11
6.2 Direction of Torque......................................................................................................................................11
6.3 Static / Quasi-Static Torques.......................................................................................................................11
6.4 Dynamic Torques.........................................................................................................................................12
6.4.1 General................................................................................................................................................12
6.4.2 Natural Resonances............................................................................................................................12
6.5 Speed Limits................................................................................................................................................12
6.6 Disturbance Variables..................................................................................................................................12
7Maintenance........................................................................................................................................................12
7.1 Maintenance Schedule................................................................................................................................12
7.2 Trouble Shooting .........................................................................................................................................13
8Decommission.....................................................................................................................................................13
9Transportation and Storage.................................................................................................................................13
9.1 Transportation .............................................................................................................................................13
9.2 Storage........................................................................................................................................................14
10 Disposal...........................................................................................................................................................14
11 Calibration .......................................................................................................................................................14
11.1 Proprietary Calibration.............................................................................................................................14
11.2 DKD-Calibration.......................................................................................................................................14
11.3 Re-Calibration..........................................................................................................................................14
12 Data Sheet.......................................................................................................................................................14

burster Italia s.r.l. · Sede legale ed operativa · Via Cesare Battisti, 16/18 · 24035 Curno (BG) · Tel. [phone] · Fax [phone]
e-mail: [e-mail] · http://www.burster.it
C.F. e P.IVA 11048400151 · Capitale sociale Euro 49.920,00 ·R.E.A. di Bergamo 276749
Apparecchi di misura di precisione. Sensori e Sistemi
per grandezze elettriche, termiche e meccaniche
1 Read First
1.1 Safety and Caution Symbols
Caution:
Injury Risk for Persons
Damage of the Device is possible.
Note:
Important points to be considered.
1.2 Intended Use
Torque sensors are intended for the measurement of torques. This measurand is further suitable for control
tasks. The valid safety regulations should be absolutely respected. The torque sensors are not safety
components in the sense of the intended use. The sensors need to be transported and stored appropriately.
The assembly, commissioning and disassembling must take place professionally.
1.3 Dangers
The torque sensor is fail-safe and corresponds to the state of technology.
1.3.1 Neglecting of Safety Notes
At inappropriate use, remaining dangers can emerge (e.g. by untrained personnel). The operation manual must
be read and understood by each person entrusted with the assembly, maintenance, repair, operation and
disassembly of the torque sensor.
1.3.2 Remaining Dangers
The plant designer, the supplier, as well as the operator must plan, realize and take responsibility for safety-
related interests for the sensor. Remaining dangers must be minimized. Remaining dangers of the torque
measurement technique must be pointed out. Human mistakes must be considered. The construction of the
plant must be suitable for the avoidance of dangers. A danger-analysis for the plant must be carried out.
1.4 Reconstructions and Modifications
Each modification of the sensors without our written approval excludes liability on our part.
1.5 Personnel
The installation, assembly, commissioning, operation and the disassembly must be carried out by qualified
personnel only. The personnel must have the knowledge and make use of the legal regulations and safety
instructions.
1.6 Warning Notes
Attention must be paid to the accident prevention regulations of the trade associations.
Coverings and casings are necessary before operating the sensor. This is also valid for
commissioning, maintenance and trouble shooting.
Duties of the coverings and casings are:
⇒Protection from detaching parts
⇒Protection from contusion and shear
⇒Prevention from reaching rotating parts
⇒Prevention from being tangled up and/or getting caught by parts
Coverings may
⇒Not grind
⇒Not rotate
Coverings are also necessary outside of operating and motion travel areas of persons.
These demands can be modified if other sufficient safety devices are available. During
operation, the safety precautions must be operative. By vibrations, damages can occur at the
device.

burster Italia s.r.l. · Sede legale ed operativa · Via Cesare Battisti, 16/18 · 24035 Curno (BG) · Tel. [phone] · Fax [phone]
e-mail: [e-mail] · http://www.burster.it
C.F. e P.IVA 11048400151 · Capitale sociale Euro 49.920,00 ·R.E.A. di Bergamo 276749
Apparecchi di misura di precisione. Sensori e Sistemi
per grandezze elettriche, termiche e meccaniche
2 Term Definitions
2.1 Terms
Measuring Side:
Mechanical connection of the torque sensor in which the torque to be measured is applied. Usually this side
has the smallest moment of inertia.
Drive Side:
Mechanical connection of the torque sensor on the opposite side of the measuring side, usually with the largest
moment of inertia. At static torque sensors the housing is fastened on this side.
Low Torque Resistance Side:
The shaft of the arrangement (drive, load) which can be turned considerably smaller with torque than the
nominal torque of the torque sensor M << Mnenn .
2.2 Definition of the Pictograms on the Torque Sensor
The measuring side of the torque sensor is designated as follows:
Measuring side:
or M
More information can be found on the data sheet, if needed.
3 Product Description
The sensor measures static and dynamic torques. The mounting position of the torque sensor is horizontally.
Caution: it is to be differentiated between measuring side and drive side, see data sheet of the sensor:
http://www.burster.it
3.1 Mechanical Setup
The sensors consist of a torsion shaft. Depending on design, the mechanical connection possibilities are
executable with round shafts or feather key connections etc. The torsion shaft, applied with two strain gauge
full bridges, is bedded in a housing through ball bearings. For the signal transmission and/or the supply of the
strain gauge full bridges, a rotating transformer, according to the principle of a transformer, is arranged in the
sensor. For supply and measuring signal conditioning, electronics are integrated in the stator and the rotor.
M

burster Italia s.r.l. · Sede legale ed operativa · Via Cesare Battisti, 16/18 · 24035 Curno (BG) · Tel. [phone] · Fax [phone]
e-mail: [e-mail] · http://www.burster.it
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3.2 Electrical Setup
The supply of the rotor electronics occurs by an alternating voltage, generated in the stator, which transfers to
the rotor through a rotating transformer. There, it is rectified and stabilized. With this supply, the strain gauge
bridge is fed.
For the electrical calibration control of the sensor, a control signal is up-modulated to the supply by the µ-
processor in the stator and transferred to the rotor. There, it is filtered and evaluated by the µPC, which also
activates the internal switch for the detuning of the strain gauge bridge.
The measuring signal of the strain gauge bridge is conditioned in an amplifier and then converted into a digital
signal, which will be transferred to the stator by another rotating transformer. Compared to the analog signal,
the measuring signal in digital form is much more disturbance-free. The remaining distance of the measuring
signal within the sensor occurs in digital form, completely. Thus, the measuring system achieves a high
reliability of operation.
This signal is further conditioned in the stator, comes into a µ-processor, then - depending upon sensor type - it
is converted to a voltage signal, digital signal or to current and will then reach the output of the sensor and can
be directly measured at the connector.
DC/ DC Oscillator
4
MHz
Signal
Conditioning
Signal Adaption
A
nalog or Digital
Signal
Conditioning
A/D-Converter
± 11 bit
± 15 bit
µ - Processor
µ-Processor
Rotation Angle (Option)
SG
Supply
Voltage
Calibration
Control
Signal
Output
Rotation
A
ngle Output
( Option)
Amplifier
Stator Rotor
Rotating Transformer
Serial Data Transmission
A
B
A
C
DC
Filter for
Control Signal
Cycle and
Control Signal
Supply and
Control Signal
Rotating Transformer
Block diagram for serial signal transmission
3.3 Sensors with Analog Output
At this output, the digital signal is converted into DC voltage of 0 V ±5 V, proportionally to the torque and is
available at the connector output.
3.4 Sensors with RS485 Interface
The torque sensor has a digital interface RS485 for the signal output and automatic sensor identification.
The protocol enables high dynamics.
See separate manual for further information.

burster Italia s.r.l. · Sede legale ed operativa · Via Cesare Battisti, 16/18 · 24035 Curno (BG) · Tel. [phone] · Fax [phone]
e-mail: [e-mail] · http://www.burster.it
C.F. e P.IVA 11048400151 · Capitale sociale Euro 49.920,00 ·R.E.A. di Bergamo 276749
Apparecchi di misura di precisione. Sensori e Sistemi
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4 Mechanical Assembly
For the assembly of a torque sensor in a shaft line, we always recommend to use couplings which can be
misaligned.
During the assembly, the sensor must be supported to protect if from falling down.
4.1 Couplings
We recommend multi-disc couplings for our torque sensors. Couplings must be able to balance an axial, radial
or angular offset of the shafts and not allow large forces to act on the sensor. The assembly instructions of the
respective coupling manufacturer must be considered.
4.1.1 Misalignment Possibilities of Single-Jointed Couplings
Note: Radial misalignments are only possible in the combination of
single-jointed coupling - torque sensor (as adapter) - single-jointed coupling.
Thus, with both single-jointed couplings the torque sensor forms a double-jointed coupling.
4.1.2 Double-Jointed Couplings
Double-jointed couplings are used for the balance of inevitable angular, axial and radial misalignments.
4.1.3 Alignment of the Measurement Arrangement
Precisely alignment of the couplings reduces the reaction forces and increases the durability of the couplings.
Disturbance variables are minimized as well.
Due to the multitude of applications, an alignment of the coupling with a straight edge in two levels, vertical to
each other, is sufficient.
However, in drives with high speed an alignment of the coupling (shaft ends) with a dial gauge or a laser is
recommended.
For further references see coupling manual.
4.2 General
Before the assembly, shafts must be cleaned with dissolver (e.g. acetone), no foreign particles may
adhere to them. The hub must fit corresponding to the connection.
Connections with Clamping Piece:
The indications of the clamping piece manufacturer must be considered. The clamping piece must be able to
transfer the arising torques safely.
Caution: During the assembly inadmissibly large forces may not act on the sensor or the couplings.
At small torques (< 20 Nm) connect the sensor electrically during the assembly and observe the
signal, the measurement signal may not exceed the limit values
Angular misalignments Axial misalignments
Radial misalignments

burster Italia s.r.l. · Sede legale ed operativa · Via Cesare Battisti, 16/18 · 24035 Curno (BG) · Tel. [phone] · Fax [phone]
e-mail: [e-mail] · http://www.burster.it
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4.2.1 Torque Sensors of 0,03 Nm to 15 Nm
Sensors with nominal torques below 20 Nm are very sensitive to overload, therefore these sensors
need to be handled with greatest caution.
1. Connect the sensor electrically during the assembly and observe the measuring signal; the limit values
may not be exceeded in any case.
2. Align the arrangement before the parts are connected firmly.
3. Assemble the sensor at the low torque resistance side first, then at the stationary side
(this avoids impermissibly large torques from acting on the sensor).
4. Counter-hold by hand, so that impermissibly large torques or disturbance variables can not act on the
torque sensor
4.2.2 Torque Sensors from 20 Nm
The hub must fit corresponding to the connection.
4.3 Freefloating Assembly
The sensor is installed between two single-jointed couplings and contributes to the
balance of an inevitable axis offset between the two mechanical connections.
If no couplings are used, very large transverse forces can affect the sensor. In
addition, large forces occur on the bearings in drive and output, which limit their life
span very strongly.
Shift couplings on shafts (use entire clamping length of the coupling) and align
shafts.
Assure absolutely that the data of the couplings (axis offset, angular offset, tension, compression) are not
exceeded.
Caution: During the assembly inadmissibly large forces may not act on the sensor or the couplings.
The housing must be protected from twisting e.g. by a flexible connection. The cable connection may not be
used for this.
The cable connection must be placed loosely (form of goose neck), so that it can follow the light movements of
the stator.
In this case, with both single-jointed couplings, the torque sensor forms a double-jointed coupling.
A single-jointed coupling can only balance axial and angular misalignments.
In this installation case, double-jointed couplings can not be used for both sides!
Risk of Breakage!
Flexible connection for
housing fixation
Drive Single-jointed coupling Single-jointed coupling Output
Torque sensor
Cable connection

burster Italia s.r.l. · Sede legale ed operativa · Via Cesare Battisti, 16/18 · 24035 Curno (BG) · Tel. [phone] · Fax [phone]
e-mail: [e-mail] · http://www.burster.it
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4.4 Foot Version Assembly
The housing of the sensor is designed as a bearing block. A full coupling must be
installed at both shaft ends. By this, inevitable misalignments can be balanced,
which can occur during the period of operation.
If no couplings are used, very large transverse forces can affect the sensor. In
addition, large forces occur on the bearings in drive and output, which limit their life
span very strongly.
Furthermore large bending moments occur in the shaft. At small torques (< 20 Nm)
connect the sensor electrically during the assembly and observe the signal, the
measurement signal may not exceed the limit values
Shafts have to be cleaned with solvent (e.g. acetone) before the assembly
No foreign bodies may adhere to them.
Shift couplings on shaft (use entire clamping length of the coupling) and align shafts.
Absolutely note that the data of the couplings (axis offset, angular offset, tension, compression) are not
exceeded.
Caution: During the assembly inadmissibly large forces may not act on the sensor or the couplings.
Double-jointed coupling Double-jointed coupling
Drive Output
Torque sensor

burster Italia s.r.l. · Sede legale ed operativa · Via Cesare Battisti, 16/18 · 24035 Curno (BG) · Tel. [phone] · Fax [phone]
e-mail: [e-mail] · http://www.burster.it
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Apparecchi di misura di precisione. Sensori e Sistemi
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12-pin
E Excitation GND
K Calibration control
5 Electrical Connection
5.1 Pin Connection
Also see test certificate.
8-pin Analog
1 Excitation + 12 ... 28 VDC
2 Excitation GND 0 V
3 Signal ±5 V / (±10 V)
4 Signal GND 0 V
5 Calibration control
L<2,0 V;
H>3,5 V
6 Option angle A TTL
7 Option angle B TTL
8 NC
View: socket on soldering side
12-
pin Analog Digital
A NC NC
B Option angle B TTL Option angle B TTL
C Signal ±5 V / (±10 V) NC
D Signal GND 0 V NC
E Excitation GND 0 V Excitation GND 0 V
F Excitation + 12 ... 28 VDC Excitation + 12 ... 28 VDC
G Option angle A TTL Option angle A TTL
H NC NC
J NC Output B RS485
K Calibration control L<2,0 V;
H>3,5 V NC
L NC Output A RS485
M Housing Housing
View: socket on soldering side
5.2 Calibration Control
Only use calibration control in unloaded condition of the torque sensor.
5.2.1 Calibration Control at Analog Output
By applying voltage of +5 V to +28 V the calibration control will switch
on.
Voltage below 2,8 V will switch off the calibration control.